Fabric footwear outsole and method of manufacturing same

ABSTRACT

The method for fabricating the fabric footwear outsole begins by forming a rubber outsole base with an unfinished exterior surface section. A non-woven fabric sheet and an unvulcanized rubber sheet are separately formed and joined together. The sheets are cut to the shape of the unfinished exterior surface section of the base to form a fabric member. The fabric member is joined to the unfinished exterior surface section of the base by glue. Thereafter, the rubber outsole base and the fabric member assembly are heated to vulcanize the rubber sheet and to securely and permanently attach the fabric member to the outsole.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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REFERENCE TO A “SEQUENCE LISTING”, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON COMPACT DISC

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to footwear constructions, particularly footwear outsoles and more particularly to a fabric footwear outsole, a method for manufacturing a fabric footwear outsole and a method of manufacturing footwear with the fabric outsole.

2. Description of Prior Art Including Information Disclosed Under 37 CFR 1.97 and 1.98

Footwear with fabric outsoles is known in the art as having certain desirable wear and traction characteristics. Various fabric footwear constructions and techniques for fabricating fabric outsoles for use in such footwear are known. Those fabricating techniques in general include molding fabric sheets to outsole bases, cementing fabric sheets within recesses formed in outsole bases and applying layers of cement to the surface of an outsole base, embedding fabric fibers into the cement using an electrostatic field and then curing the cement. However, none of those methods produce a product with a fabric outsole that is sufficiently durable, at a price that is competitive with comparable products with all rubber outsoles.

BRIEF SUMMARY OF THE INVENTION

It is, therefore, a prime object of the present invention to provide a fabric footwear outsole.

It is another object of the present invention to provide footwear with a fabric outsole.

It is another object of the present invention to provide a method for manufacturing a fabric footwear outsole.

It is another object of the present invention to provide a method for manufacturing footwear with a fabric outsole.

It is another object of the present invention to provide a fabric footwear outsole formed of a rubber outsole base with a fabric member joined thereto.

It is another object of the present invention to provide a fabric footwear outsole including a fabric member formed of a fabric sheet cemented to a rubber sheet.

It is another object of the present invention to provide a fabric footwear outsole with a fabric member wherein the rubber sheet remains unvulcanized until after the outsole components are assembled.

It is another object of the present invention to provide a fabric footwear outsole with a fabric member wherein the rubber sheet is vulcanized after the other outsole components are assembled in order to securely and permanently attach the fabric member to the outsole base.

It is another object of the present invention to provide footwear with a fabric outsole formed as described herein.

The above objects are achieved by the present invention, one aspect of which relates to method of fabricating a fabric footwear outsole. The method begins by forming a rubber outsole base with an unfinished exterior surface section. A non-woven fabric sheet and an unvulcanized rubber sheet are formed and joined together. The sheets are cut to the shape of the unfinished exterior surface section of the base to form a fabric member. The fabric member is joined to the unfinished exterior surface section of the base. Thereafter, the rubber outsole base and the fabric member assembly is heated to form the outsole.

The step of forming the rubber outsole base includes forming a rubber outsole base with a finished exterior surface section. The finished exterior surface section is formed proximate the unfinished exterior surface section of the base.

The step of joining the rubber sheet and the fabric sheet includes cementing the sheets together. The rubber sheet and the fabric sheet may be squeezed together during the joining process.

The step of forming an unvulcanized rubber sheet includes forming an unvulcanized rubber sheet approximately 1 mm in thickness. The sheet may be formed by squeezing unvulcanized rubber into a sheet.

The steps of forming an unvulcanized rubber sheet and forming the fabric sheet may take place simultaneously, in a single machine.

Preferably, the surface of the non-woven fabric is embossed to provide a textured surface. The embossing step can take place before or after the joined fabric sheet and unvulcanized rubber sheet is cut to size.

The method further comprises the step of buffing the surface of the unfinished exterior surface section of the base prior to joining the fabric member thereto.

The step of joining the fabric member to the unfinished exterior surface section includes cementing the fabric member to the unfinished exterior surface section. Rubber glue may be used for that purpose.

In accordance with another aspect of the present invention, a method of fabricating footwear with a fabric outsole is provided. The method begins by forming a rubber outsole base with an unfinished exterior surface section. A non-woven fabric sheet and an unvulcanized rubber sheet are formed and joined together. The sheets are cut to the shape of the unfinished exterior surface section of the base to form a fabric member. The fabric member is joined to the unfinished exterior surface section of the base. Thereafter, the rubber outsole base and the fabric member assembly is heated to form the fabric outsole. An upper is formed and attached to the fabric outsole to complete the footwear.

The step of forming the rubber outsole base includes forming a rubber outsole base with a finished exterior surface section. The finished exterior surface section is formed proximate the unfinished exterior surface section of the base.

The step of joining the rubber sheet and the fabric sheet includes cementing the sheets together. The rubber sheet and the fabric sheet may be squeezed together during the joining process.

The step of forming an unvulcanized rubber sheet includes forming an unvulcanized rubber sheet approximately 1 mm in thickness. The sheet may be formed by squeezing unvulcanized rubber into a sheet.

The steps of forming an unvulcanized rubber sheet and forming the fabric sheet may take place simultaneously, in a single machine.

Preferably, the surface of the non-woven fabric is embossed to provide a textured surface.

In accordance with another aspect of the present invention, an outsole with a fabric member is provided. The outsole includes a rubber outsole base with an exterior surface having an unfinished section of a given shape and a fabric member substantially of the same shape as the unfinished base section. The fabric member includes a fabric layer and a rubber layer. Means are provided for joining the fabric member to the unfinished section of the base.

The rubber layer is unvulcanized prior to forming the fabric member.

The base and the fabric member are heated subsequent to being joined.

In accordance with another aspect of the present invention, footwear with a fabric outsole is provided. The outsole includes a rubber outsole base with an exterior surface having an unfinished section of a given shape and a fabric member substantially of the same shape as the unfinished base section. The fabric member includes a fabric layer and a rubber layer. Means are provided for joining the fabric member to the unfinished section of the base to form the fabric outsole. An upper is provided as are means for attaching the upper to the fabric outsole.

The rubber layer is unvulcanized prior to forming the fabric member.

The base and the fabric member are heated subsequent to being joined.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF DRAWINGS

To these and to such other objects that may hereinafter appears, the present invention relates to a fabric footwear outsole, footwear with a fabric outsole, a method for fabricating a fabric footwear outsole and a method for fabricating footwear with a fabric outsole as described in detail in the following specification and recited in the annexed claims, taken together with the accompanying drawings, in which like numerals refer to like parts and in which:

FIG. 1 is a perspective view of a shoe with the fabric outsole of the present invention;

FIG. 2 is a perspective view of a machine joining the fabric sheet and unvulcanized sheet and embossing same.

FIG. 3 is a more detailed view of the sheets prior to embossing as seen in the dashed circle labeled 3 of FIG. 2;

FIG. 4 is a more detailed view of the sheets after embossing as seen in the dashed circle labeled 4 of FIG. 2;

FIG. 5 illustrated the step of cutting the sheets to the size and shape of the unfinished base section to form the fabric member;

FIG. 6 is a perspective view of the outsole base;

FIG. 7 is a perspective view of the outsole base as the unfinished section is buffed;

FIG. 8 is a perspective view of the outsole base as rubber cement is applied to the unfinished section;

FIG. 9 is an exploded perspective view of the outsole base and the fabric member before the fabric member is placed on the layer of rubber glue; and

FIG. 10 is a perspective view of the fully assembled fabric outsole as it is being vulcanized.

DETAILED DESCRIPTION OF THE INVENTION

The fabrication process begins, as illustrated in FIG. 2, by joining a continuous non-woven fabric sheet 10 fed from a supply roller 12 with a continuous unvulcanized rubber sheet 14 fed from a supply roller 16. The rubber sheet is preferably approximately 1 mm thick as it comes from the roller. The sheets are joined using a layer of rubber glue 18 supplied from a glue supply tray 20.

Pressure is applied to the sheets, with the glue layer 18 therebetween, to squeeze the sheets together. The pressure is applied by pressure rollers 22. After passing between the pressure rollers, the sheets appear as seen in FIG. 3.

In one preferred embodiment, the sheets then pass under an embossing roller 24 which imparts a herring bone like pattern on the surface thereof, as illustrated in FIG. 4. In that case, the fabric members 26 are formed from the glued and embossed sheets by die cutting the embossed sheets into sections of the desired size and shape. The members are cut by a reciprocating die 28, as seen in FIG. 5.

In a second preferred embodiment, the sheets pass through the reciprocating die 28 of the die cutting press, as illustrated in FIG. 5, and then the cut members 26 are embossed by an embossing roller, so as to appear as illustrated in FIG. 4.

Separately, an outsole base, generally designated 30, made of rubber or other flexible material is formed in a conventional manner except that the bottom surface of base 30 has three distinct surface sections. The central section 32 of the base surface is unfinished. The toe section 34 and the heel section 36 are finished and preferably have embossed or roughened surfaces.

Central section 32 of base 30 is recessed relative to the toe and heel sections 32 and 34 by a distance equal to the thickness of fabric member 26 such that when the fabric member is received in the recess, the surface of the fabric member will be coplanar with the surface of the toe section and of the heel section. Further, the interior edge of toe section 34 is adjacent to the front edge of unfinished section 32. Likewise, the interior edge of heel section 36 is adjacent to the rear edge of unfinished section 32. Accordingly, once the fabric member is in place on the base, the exposed surface of the fabric member and the exposed surfaces of toe and heel sections of the base form a single planar sectioned surface suitable for use as a footwear outsole.

Prior to mounting the fabric member on the base, the unfinished section 32 of the base surface is buffed using spaced buffing rollers 38, 40, as illustrated in FIG. 7. After buffing, a layer of rubber glue 42 is applied to the surface of the unfinished section by a movable nozzle 46, as seen in FIG. 8. The fabric member 26, which has been cut to have the same size and shape as the unfinished section 32 of base 30, is then placed onto layer 42 of rubber glue previously deposited over the unfinished base section. The assembly, as shown in FIG. 10 is heated in order to vulcanize the rubber layer formed from sheet 14. The heat causes that rubber layer to cure and to securely and permanently attach the fabric member to the unfinished section of the surface of the base.

The shoe is completed by securing the upper 48 to the completed fabric outsole 50, as illustrated in FIG. 1. The upper can be attached to the outsole using any conventional method, such as glue, stitching or a combination thereof.

As will now be appreciated, the present invention relates to a method for fabricating a fabric footwear outsole. The method begins by forming a rubber outsole base with an unfinished exterior surface section. A non-woven fabric sheet and an unvulcanized rubber sheet are formed and joined together. The sheets are cut to the shape of the unfinished exterior surface section of the base to form a fabric member. The fabric member is joined to the unfinished exterior surface section of the base. Thereafter, the rubber outsole base and the fabric member assembly is heated to vulcanize the rubber layer of the fabric member to secure and permanently attach the fabric member to the outsole base.

The rubber outsole base has a finished exterior surface section proximate the unfinished exterior surface section of the base.

The rubber sheet is joined to the fabric sheet by cementing the sheets together. The rubber sheet and the fabric sheet may be squeezed together during the joining process. Preferably, the rubber sheet has a thickness of approximately 1 mm. The sheet may be formed by squeezing unvulcanized rubber into a sheet. The forming of the rubber sheet and forming the fabric sheet may take place simultaneously, in a single machine.

Preferably, the surface of the non-woven fabric is embossed to provide a textured surface. The embossing step can take place before or after the sheets are die cut to form the fabric members. The surface of the unfinished exterior surface section of the base is preferably buffed prior to joining the fabric member thereto. The fabric member is joined to the unfinished exterior surface section by rubber glue.

The completed outsole may then be attached to an upper, using conventional methods, to form the shoe.

It will be further appreciated that the present invention also relates to the fabric outsole itself. The outsole includes a rubber outsole base with an exterior surface having an unfinished section of a given shape and a fabric member substantially of the same shape as the unfinished base section. The fabric member includes a fabric layer and a rubber layer. Means are provided for joining the fabric member to the unfinished section of the base. The rubber layer is unvulcanized prior to forming the fabric member. The base and the fabric member are heated subsequent to being joined to secure and permanently affix the fabric member to the outsole base.

While only a single preferred embodiment of the present invention has been disclosed for purposes of illustration, it is obvious that many modifications and variations could be made thereto. It is intended to cover all of those modifications and variations which fall within the scope of the present invention, as defined by the following claims. 

1. A method of fabricating an outsole comprising the steps of: (a) forming a rubber outsole base with an unfinished exterior surface section; (b) forming a non-woven fabric sheet; (c) forming an unvulcanized rubber sheet; (d) joining the sheets; (e) cutting the joined sheets to the shape of the unfinished exterior surface section to form a fabric member; (f) joining the fabric member to the unfinished exterior surface section of said base to form an assembly; and (g) heating the assembly to vulcanize the rubber sheet and permanently secure the fabric member to said base to form the outsole.
 2. The method of claim 1 wherein the step of forming the rubber outsole base comprises the step of forming the rubber outsole base with a finished exterior surface section.
 3. The method of claim 1 wherein the step of forming the rubber outsole base comprises the step of forming the rubber base with a finished exterior surface section proximate the unfinished exterior surface section.
 4. The method of claim 1 wherein the step of joining the rubber sheet and the fabric sheet comprises the step of cementing the sheets together.
 5. The method of claim 1 wherein the step of joining the rubber sheet and the fabric sheet comprises squeezing the sheets together.
 6. The method of claim 4 wherein the step of joining the rubber sheet and the fabric sheet further comprises squeezing the sheets together.
 7. The method of claim 1 wherein the step of forming an unvulcanized rubber sheet comprises the step of forming an unvulcanized rubber sheet approximately 1 mm in thickness.
 8. The method of claim 1 wherein the step of forming an unvulcanized rubber sheet comprises the step of squeezing unvulcanized rubber into a sheet.
 9. The method of claim 1 wherein the steps of forming an unvulcanized rubber sheet and forming the fabric sheet take place simultaneously.
 10. The method of claim 1 further comprising the step of embossing the surface of the non-woven fabric.
 11. The method of claim 1 further comprising the step of buffing the surface of the unfinished exterior surface section prior to joining the fabric member thereto.
 12. The method of claim 1 wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section.
 13. The method of claim 1 wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section with rubber glue.
 14. A method of fabricating footwear with a fabric outsole comprising the steps of: (a) forming a rubber outsole base with an unfinished exterior surface section; (b) forming a non-woven fabric sheet; (c) forming an unvulcanized rubber sheet; (d) joining the sheets; (e) cutting the joined sheets to the shape of the unfinished exterior surface section to form a fabric member; (f) joining the fabric member to the unfinished exterior surface section; (g) heating the assembly to vulcanize the rubber sheet and permanently secure the fabric member to said base to form the outsole; (h) forming an upper; and (i) attaching the upper to the outsole.
 15. The method of claim 14 wherein the step of forming the rubber outsole base comprises the step of forming a rubber outsole base with a finished exterior surface section.
 16. The method of claim 15 wherein the step of forming the rubber outsole base comprises the step of forming a rubber outsole base with a finished exterior surface section proximate the unfinished exterior surface section.
 17. The method of claim 14 wherein the step of joining the rubber sheet and the fabric sheet comprises the step of cementing the sheets.
 18. The method of claim 14 wherein the step of joining the rubber sheet and the fabric sheet comprises squeezing the sheets together.
 19. The method of claim 18 wherein the step of joining the rubber sheet and the fabric sheet comprises squeezing the sheets together.
 20. The method of claim 14 wherein the step of forming an unvulcanized rubber sheet comprise the step of forming an unvulcanized rubber sheet 1 mm in thickness.
 21. The method of claim 14 wherein the step of forming an unvulcanized rubber sheet comprises the step of squeezing unvulcanized rubber into a sheet.
 22. The method of claim 14 wherein the step of forming an unvulcanized rubber sheet and the fabric sheet take place simultaneously.
 23. The method of claim 14 further comprising the step of embossing the surface of the fabric.
 24. The method of claim 14 further comprising the step of buffing the surface of the unfinished exterior surface section prior to joining the fabric member thereto.
 25. The method of claim 14 wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section.
 26. The method of claim 14 wherein the step of joining the fabric member to the unfinished exterior surface section comprises the step of cementing the fabric member to the unfinished exterior surface section with rubber glue.
 27. An outsole with a fabric member comprising a rubber outsole base with an exterior surface comprising an unfinished section of a given shape and size; a fabric member substantially of said given shape and size comprising a fabric layer and a rubber layer, and means for joining said fabric member to said unfinished section of said base.
 28. The outsole of claim 27 wherein said base and said fabric member are heated to vulcanize said rubber sheet subsequent to being joined.
 29. The outsole of claim 27 wherein said rubber layer is unvulcanized prior to forming said fabric member. 